Insulation material

ABSTRACT

An improved insulation system. The improved insulation system includes: an insulation component further including an expansion ratio modifying agent, a compression package, wherein the packed insulation density is greater than the installed insulation density, and a secondary container for receiving the compression package.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates generally to loose fill insulation, and more specifically to a pourable loose fill insulation that may be installed by pouring the insulation into the area to be insulated without blowing.

(2) Description of the Prior Art

Generally, to install loose fill insulation, it is necessary to use a blower. Insulation is often compacted during packaging and shipment so as to reduce shipping costs, thereby requiring a blower to install the insulation. However, since one-half of all insulation sales are for jobs covering only up to 200 square feet, it can be costly to rent or buy a blower. Further, many blowers are bulky and difficult for a do-it-yourselfer to operate. Thus, for small insulation installations especially, blowing insulation is often impractical.

Further, though rolls of insulation are available, rolling out insulation can be more difficult than would first appear. Blowing insulation is often easier than rolling out insulation.

Thus, there remains a need for a new and improved, pourable insulation material, which may be installed by pouring the product straight from the bag and packaged in such a way that the package density of the insulation is at least about equal to the density of the insulation at installation.

SUMMARY OF THE INVENTION

The present invention is directed to an improved, pourable insulation material system. The improved insulation system may include: (a) an insulation component further including an expansion ratio modifying agent, (b) a compression package, wherein the packed insulation density is greater than the installed insulation density, and (c) a secondary container for receiving the compression package.

Also in the preferred embodiment, the insulation material may be selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material, aggregated material and mixtures thereof. The insulation material may also be an inorganic material selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, asbestos, and mixtures thereof.

In the preferred embodiment, the insulation material may also be organic. The organic material may be a natural material. The natural material may be cellulosic.

The insulation material may also be a non-conductive material. Preferably, the non-conductive material may be a thermally non-conductive material or an acoustically non-conductive material. The non-conductive material may be an electrically non-conductive material.

In the preferred embodiment, the insulation system may further include an expansion ratio modifying agent (ERMA). Preferably, the expansion ratio modifying agent is a fiber or a particulate. Also preferably, the expansion ratio modifying agent may be selected from the group consisting of: synthetic or natural fibers such as polypropylene, polyethylene, nylon, polyester or polyester terephthalate, cotton, hemp, glass, mineral wool, and mixtures thereof. The fibers may be chopped to a specific average length or continuous and of indeterminate length. The fibers of a determinate length may have various aspect ratios of fiber length to fiber diameter.

Also in the preferred embodiment, the amount of expansion ratio modifying agent may be greater than about 1 wt. %. Preferably, the amount of expansion ratio modifying agent may be between about 1 wt. % and 20 wt. %.

In the preferred embodiment, the insulation system may further include an expansion ratio coloring agent (ERCA). The ERCA may be inorganic. Preferably, the ERCA is selected from the group consisting of: inorganic and organic pigments, dyes, tints, or materials that contain a coloring agent, or materials that have color that is present for another use and not to impart color to the original material or the insulation system, and mixtures thereof. The materials may be natural or synthetic.

Preferably, the compression package may be gravity dispensed. Further, the package may be a preformed bag. Further, the package may have improvements such as slots, braces, holes, or other devices or designs to enhance the expansion of the product during application so that a greater expansion from high to low density at installation can be made. In the preferred embodiment, the ratio of the packed insulation density to the installed insulation density is between about 3½ and 10 to 1.

Also, in the preferred embodiment, the secondary container may be flexible, semi-rigid, or rigid. The secondary container may be a Gaylord package. Preferably, the secondary container may be adapted to receive a plurality of packages.

Accordingly, one aspect of the present invention is to provide an improved, pourable insulation material system. The system may include: (a) an insulation component, and (b) a compression package, wherein the packed insulation density is about equal to the installed insulation density.

Another aspect of the present invention is to provide an improved, pourable insulation material system. The system may include: (a) an insulation component further including an expansion ratio modifying agent, and (b) a compression package, wherein the packed insulation density is greater than the installed insulation density.

Still another aspect of the present invention is to provide an improved, pourable insulation material system. The system may include: (a) an insulation component further including an expansion ratio modifying agent, (b) a compression package, wherein the packed insulation density is greater than the installed insulation density, and (c) a secondary container for receiving the compression package.

These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a compression package filled with insulation constructed according to the present invention;

FIG. 2 is an illustration of a Gaylord package filled with several compression packages constructed according to the present invention; and

FIG. 3 is a graphical representation of the expansion ratio versus the expansion ratio modifying agent concentration showing the increased expansion ratio of the insulation product as the concentration of the expansion ratio modifying agent increases.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.

Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto.

As best seen in FIG. 1, an improved pourable insulation material system 10 is shown. The system includes an insulation component 12 and a compression package 14. The density of the packed insulation is at least about equal to the insulation density after installation 16.

Generally, the insulation component 12 is selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material, aggregated material and mixtures thereof. Also, the insulation component 12 is inorganic, and is selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, asbestos, and mixtures thereof. Alternatively, the insulation component 12 is organic.

The organic material is a natural material, and is cellulosic. The insulation component 12 is a non-conductive material, and is a thermally non-conductive material or an acoustically non-conductive material. The non-conductive material is an electrically non-conductive material.

Also as seen in FIG. 1, the package 14 is gravity dispensed. Further, in the preferred embodiment, the package 14 is a pre-formed bag.

Turning now to FIG. 2, there is shown a secondary container 16 for receiving the compression package 14. The secondary container 16 is semi-rigid. Further, the secondary container 16 is a Gaylord package. Also, the secondary container 16 is adapted to receive a plurality of compression packages 14.

Preferably, the ratio of the packed insulation density to the installed insulation density is between about 3½ and 10 to 1.

In the preferred embodiment, the insulation system includes an expansion ratio expansion ratio modifying agent (ERMA). The ERMA is preferable a fiber or a particulate. Further, the ERMA may be selected from the group consisting of: synthetic or natural fibers such as polypropylene, polyethylene, nylon, polyester or polyester terephthalate, cotton, hemp, glass, mineral wool, and mixtures thereof. In the most preferred embodiment, the ERMA is chopped polyester terephthalate (PET) fiber.

As best seen in FIG. 3, there is shown a graphical representation of the effect of the wt. % of ERMA on the expansion ratio (ER) of the insulation material. As used herein, ER is the ratio of packed density to poured density of the insulation material. Generally, the amount of ERMA is greater than about 1 wt. % with between about 1 wt. % and 20 wt. % being the preferred range.

As can be seen, the curve of ER v. wt. % of ERMA unrepentantly flattens out to almost a horizontal line above about 20 wt. % ERMA for a cellulose/PET fiber insulation/ERMA system. Additional amounts of ERMA appear to provide little improvement in ER for this particular insulation system.

While, it is believed that the ER will behave differently in other fiber type insulation systems, such as fiberglass insulation, those systems should generally follow the relationship illustrated in FIG. 3.

Another unexpected result is that this expansion upon pouring occurs without further manipulation, such as blowing, of the fiber matrix. Typically, in the prior art, when opening a bag of cellulose insulation, there is no expansion per se without further manipulation such as with a blowing machine. The product comes out in unexpanded clumps. This is true even when paper mulch has seed and fertilizer added to it, in which case, it falls to the ground and has to be spread by hand, thus opening the fiber through manual manipulation. Accordingly, cellulose and chopped fiberglass insulation, for example, are generally blown in order to cause the insulation to expand greater than its packed density. However, in the present invention, the expansion ratio exists even when there is no further manipulation upon the part of the installer beyond simple leveling of the poured mass. Little or any further energy or special equipment is required to produce a satisfactory expansion.

Finally, as used herein, “pourability” is particularly intended to describe the ability of insulation systems constructed according to the present invention to reach the ER without further manipulation. However, “pourability” also refers generally to the additional ability of the insulation system of the present invention to exit its bag easily.

The insulation system may further include an expansion ratio coloring agent (ERCA). In the preferred embodiment, the ERCA is inorganic. The inorganic ERCA may be selected from the group consisting of: inorganic and organic pigments, dyes, tints, or materials that contain a coloring agent, or materials that have color that is present for another use and not to impart color to the original material or the insulation system, and mixtures thereof. The materials may be natural or synthetic.

Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. For instance, the insulation may include a fire retardant component. Further, the insulation may contain pesticides, such as herbicides, fungicides, rodenticides, insecticides, and other pest preventing agents. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims. 

1. An improved insulation material system, said system comprising: (a) an insulation component; and (b) a compression package, wherein the packed insulation density is about equal to the installed insulation density.
 2. The insulation system according to claim 1, further including a secondary container for receiving the compression package.
 3. The insulation system according to claim 2, wherein the secondary container is semi-rigid.
 4. The insulation system according to claim 3, wherein the secondary container is a Gaylord package.
 5. The insulation system according to claim 2, wherein the secondary container is adapted to receive a plurality of packages.
 6. The insulation system according to claim 1, wherein the insulation component is selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material, aggregated material and mixtures thereof.
 7. The insulation system according to claim 1, wherein the insulation component is inorganic.
 8. The insulation system according to claim 7, wherein the inorganic component is selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, asbestos, and mixtures thereof.
 9. The insulation system according to claim 1, wherein the insulation component is organic.
 10. The insulation system according to claim 9, wherein the organic material is a natural material.
 11. The insulation system according to claim 10, wherein the natural material is cellulosic.
 12. The insulation system according to claim 1, wherein the insulation component is a non-conductive material.
 13. The insulation system according to claim 12, wherein the non-conductive material is a thermally non-conductive material.
 14. The insulation system according to claim 12, wherein the non-conductive material is an acoustically non-conductive material.
 15. The insulation system according to claim 12, wherein the non-conductive material is an electrically non-conductive material.
 16. The insulation system according to claim 1, wherein the package is gravity dispensed.
 17. The insulation system according to claim 1, wherein the package is a pre-formed bag.
 18. An improved insulation material comprising: (a) an insulation component further including an expansion ratio modifying agent; and (b) a compression package, wherein the packed insulation density is greater than the installed insulation density.
 19. The insulation system according to claim 18, wherein the ratio of the packed insulation density to the installed insulation density is between about 3½ and 10 to
 1. 20. The insulation system according to claim 18, wherein the expansion ratio modifying agent is a fiber.
 21. The insulation system according to claim 18, wherein the expansion ratio modifying agent is a particulate.
 22. The insulation system according to claim 18, wherein the expansion ratio modifying agent is selected from the group consisting of: synthetic or natural fibers such as polypropylene, polyethylene, nylon, polyester or polyester terephthalate, cotton, hemp, glass, mineral wool, and mixtures thereof.
 23. The insulation system according to claim 18, wherein the amount of expansion ratio modifying agent is greater than about 1 wt. %.
 24. The insulation system according to claim 23, wherein the amount of expansion ratio modifying agent is between about 1 wt. % and 20 wt. %.
 25. The insulation system according to claim 18, further including an expansion ratio coloring agent (ERCA).
 26. The insulation system according to claim 25, wherein the ERCA is inorganic.
 27. The insulation system according to claim 25, wherein the ERCA is selected from the group consisting of: inorganic and organic pigments, dyes, tints, or materials that contain a coloring agent, or materials that have color that is present for another use and not to impart color to the original material or the insulation system, and mixtures thereof.
 28. An improved insulation material system, said system comprising: (a) an insulation component further including an expansion ratio modifying agent; (b) a compression package, wherein the packed insulation density is greater than the installed insulation density; and (c) a secondary container for receiving the compression package.
 29. The insulation system according to claim 28, wherein the secondary container is semi-rigid.
 30. The insulation system according to claim 29, wherein the secondary container is a Gaylord package.
 31. The insulation system according to claim 28, wherein the secondary container is adapted to receive a plurality of packages.
 32. The insulation system according to claim 28, wherein the insulation component is selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material, aggregated material and mixtures thereof.
 33. The insulation system according to claim 28, wherein the insulation component is inorganic.
 34. The insulation system according to claim 33, wherein the inorganic component is selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, asbestos, and mixtures thereof.
 35. The insulation system according to claim 28, wherein the insulation component is organic.
 36. The insulation system according to claim 35, wherein the organic material is a natural material.
 37. The insulation system according to claim 36, wherein the natural material is cellulosic.
 38. The insulation system according to claim 28, wherein the insulation component is a non-conductive material.
 39. The insulation system according to claim 38, wherein the non-conductive material is a thermally non-conductive material.
 40. The insulation system according to claim 38, wherein the non-conductive material is an acoustically non-conductive material.
 41. The insulation system according to claim 38, wherein the non-conductive material is an electrically non-conductive material.
 42. The insulation system according to claim 28, wherein the package is gravity dispensed.
 43. The insulation system according to claim 28, wherein the package is a pre-formed bag.
 44. The insulation system according to claim 28, wherein the ratio of the packed insulation density to the installed insulation density is between about 3½ and 10 to
 1. 45. The insulation system according to claim 28, wherein the expansion ratio modifying agent is a fiber.
 46. The insulation system according to claim 28, wherein the expansion ratio modifying agent is a particulate.
 47. The insulation system according to claim 28, wherein the expansion ratio modifying agent is selected from the group consisting of: synthetic or natural fibers such as polypropylene, polyethylene, nylon, polyester or polyester terephthalate, cotton, hemp, glass, mineral wool, and mixtures thereof.
 48. The insulation system according to claim 28, wherein the amount of expansion ratio modifying agent is greater than about 1 wt. %.
 49. The insulation system according to claim 48, wherein the amount of expansion ratio modifying agent is between about 1 wt. % and 20 wt. %.
 50. The insulation system according to claim 28, further including an expansion ratio coloring agent (ERCA).
 51. The insulation system according to claim 50, wherein the ERCA is inorganic.
 52. The insulation system according to claim 50, wherein the ERCA is selected from the group consisting of: inorganic and organic pigments, dyes, tints, or materials that contain a coloring agent, or materials that have color that is present for another use and not to impart color to the original material or the insulation system, and mixtures thereof. 